Electrode Assembly and Apparatus and Method for Manufacturing the Same

ABSTRACT

An apparatus for manufacturing an electrode assembly includes a separator supply unit, table, separator guide, first adhesive supply unit, and pair of tensioners. The separator supply unit is configured for supplying a separator sheet from which a separator is formed. The table is configured for supporting electrodes and sections of the separator sheet. The separator guide is configured for guiding the separator sheet to fold in a particular folding direction. The first adhesive supply unit is configured for applying an adhesive to portions of the separator sheet and the electrodes supported by the table. The pair of tensioners are each configured for pressing an uppermost section of the separator sheet guided by the separator guide against the table or against a placed electrode that directly underlies the uppermost section. The electrode assembly is manufactured by a process using the apparatus.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority from Korean Patent Application Nos. 2021-0124049, filed on Sep. 16, 2021, 2021-0124050, filed on Sep. 16, 2021, and 2021-0124051, filed on Sep. 16, 2021, the disclosures of which are hereby incorporated herein by reference in their entireties.

FIELD

The present disclosure relates to an electrode assembly, e.g., one for use in a battery cell, an apparatus for manufacturing the electrode assembly, and a method for manufacturing the electrode assembly, and more particularly, to an electrode assembly in which an electrode and a separator sheet are stacked in a Z-folding (i.e., zigzag-folding) type and the electrode is at least inhibited from being separated from a fixed relative position in the electrode assembly along with an apparatus and a method for manufacturing such an electrode assembly.

BACKGROUND

Generally, the types of secondary batteries (e.g., rechargeable batteries) include nickel-cadmium batteries, nickel-hydrogen batteries, lithium-ion batteries, lithium-ion polymer batteries, and the like. Such secondary batteries are used, not only for smaller applications and in smaller-sized products such as digital cameras, P-DVD, MP3P, cellular phones, PDA, portable game devices, power tools and E-bikes, but also for larger applications and in larger-sized products demanding high output, such as electric and hybrid vehicles and power storage devices which may be used for storing surplus generated power or new renewable energy or for providing backup power.

In order to manufacture such a secondary battery, first, an electrode active material slurry is applied to a cathode current collector and an anode current collector to prepare a cathode and an anode, which are respectively stacked on opposite sides of a separator, thereby forming an electrode assembly having a predetermined shape. Then, the electrode assembly is housed in a battery case, an electrolytic solution is injected, and the case is then sealed to form a battery cell.

Electrode assemblies are classified into various types. For example, a simple stack type is one in which cathodes, separators, and anodes simply overlap with each other and are continuously stacked without manufacturing a unit cell (e.g., an elementary or fundamental battery unit comprising a cathode, a separator, and an anode), a lamination & stack (L&S) type is one in which unit cells are first manufactured using cathodes, separators, and anodes and then stacked, a stack & folding (S&F) type is one in which a plurality of unit cells are spaced apart and attached to one surface of an elongated separator sheet and the separator sheet is repeatedly folded in the same direction from one end, the Z-folding type in which a plurality of electrodes or unit cells are alternately attached to one surface and the other surface of an elongated separator sheet, and the separator sheet is repeatedly folded in alternating directions starting from one end of the separator sheet, and the like. Among them, the Z-folding type has high degrees of alignment and electrolytic solution impregnation, and thus this type has often been used in recent years.

Moreover, conventionally, after the electrodes and the separator sheet are stacked in this Z-folding type, no separate laminating process is performed such that, due to the electrodes and the separator sheet being separable at this juncture in the process, the electrodes become displaced from their fixed positions in the electrode assembly. To solve this problem, a separate stacking alignment process is often performed after stacking the electrodes and the separator sheet, but this process can increase the overall thickness of the stacked body of the electrodes and the separator sheet such that heat is not sufficiently transferred to the interior of the stacked body and the adhesive strength is lowered. Additionally, even when a separate stacking alignment process is performed, the electrodes can be displaced from their fixed positions in the electrode assembly during the process of transferring the stacked body. This problem can be further aggravated depending on the material of the separator sheet when the adhesive strength of the separator sheet itself is low.

Therefore, there is a need to develop a Z-folding type electrode assembly having improved performance in use, e.g., when used in battery cells, while preventing relative displacement of the electrodes from their fixed positions in the electrode assembly as well as an apparatus and method for manufacturing such an assembly.

SUMMARY OF THE DISCLOSURE

It is an object of the present disclosure to provide an electrode assembly, which may be for use in a battery cell and further in a battery, in which electrodes and a separator sheet may be stacked in a Z-folding type and the electrodes may be prevented or otherwise inhibited from being displaced from a fixed position relative to the electrode assembly. An apparatus and a method for manufacturing such an electrode assembly are further objects of this disclosure.

The objects of the present disclosure are not limited to the aforementioned objects, and other objects which are not expressly described herein should be clearly understood to be encompassed by the present disclosure by those skilled in the art from the following detailed description and the accompanying drawings.

According to an aspect of the present disclosure, an apparatus for manufacturing an electrode assembly may include a separator supply unit, a table, a separator guide, a first adhesive supply unit, and a pair of tensioners. The electrode assembly, after being manufactured, may include a plurality of electrodes and a separator that may be folded in a zigzag manner around alternating side portions of each of the electrodes and may cover upper and lower surfaces of each of the electrodes. The separator supply unit may be configured for supplying a separator sheet from which the separator is formed. The table may be configured for supporting the plurality of electrodes and sections of the separator sheet. A separator guide may be configured for guiding the separator sheet to fold in a preset or otherwise particular folding direction. The first adhesive supply unit may be configured for applying an adhesive to either one or both of at least a part of the separator sheet, which may be some or all of the sections of the separator sheet, and at least one of the plurality of electrodes supported by the table. Either one or both of the pair of tensioners may be configured for pressing the separator sheet guided by the separator guide.

In some arrangements of the apparatus for manufacturing an electrode assembly, the pair of tensioners may be located between the table and the separator guide when the pair of tensioners, the table, and the separator guide are aligned along an axis and relative to a plane.

In some arrangements, the apparatus for manufacturing the electrode assembly may further include a first electrode supply unit configured for supplying a first electrode sheet. In some such arrangements, the first electrode supply unit may be a first electrode reel from which the first electrode sheet, on which a plurality of first electrodes of the plurality of electrodes may be formed, may be unwound. In some such arrangements, the apparatus may further include a second electrode supply unit. In such arrangements, the second electrode supply unit may be a second electrode reel from which a second electrode sheet, on which a plurality of second electrodes of the plurality of electrodes may be formed, may be unwound.

In some arrangements, the separator supply unit may be a separator reel from which the separator sheet may be unwound when the separator sheet is supplied by the separator supply unit.

In some arrangements, the apparatus for manufacturing an electrode assembly may further include a first transfer device and a second transfer device. The first transfer device may be configured for conveying or otherwise transferring one of the first electrodes toward the table. The second transfer device may be configured for conveying or otherwise transferring the second electrode toward the table. In some such arrangements, the first transfer device and the second transfer device may be arranged to be on opposite sides of the separator sheet supplied from the separator supply unit.

In some arrangements of the apparatus for manufacturing an electrode assembly, the first electrode may be seated on a first region of the separator sheet in which the first region may be on one side of a first section of the separator sheet. In some such arrangements, the second electrode may be seated on a second region of the separator sheet in which the second region may be on one side of a second section of the separator sheet.

In some arrangements, the apparatus for manufacturing an electrode assembly may further include a first header that may be configured for adsorbing the first electrodes and then seating the adsorbed first electrodes on the first region of the first section of the separator sheet. In some such arrangements, a second header may be configured for adsorbing the second electrodes and then seating the adsorbed second electrodes on the second region of the section of the separator sheet. In some such arrangements, the first header and the second header are arranged to be on opposite sides of the separator sheet supplied from the separator supply unit.

In some arrangements of the apparatus for manufacturing an electrode assembly, the separator guide, the first adhesive supply unit, and the pair of tensioners may be fixed at their respective positions. In such arrangements, the table may be configured for translation, e.g., linearly, in a first direction toward the first transfer device and in a second direction toward the second transfer device.

In some arrangements of the apparatus for manufacturing an electrode assembly, the table may be fixed at a position. In some such arrangements, each of the separator guide, the first adhesive supply unit, and the pair of tensioners may be configured for translation, e.g., linearly, in a first direction toward the first transfer device and in a second direction toward the second transfer device.

In some arrangements, the apparatus for manufacturing an electrode assembly may further include a moveable frame configured for carrying the separator guide and the first adhesive supply unit. In some such arrangements, the moveable frame may be configured for substantially enclosing the separator guide and the first adhesive supply unit. In some such arrangements, the moveable frame may be in the form of a box having openings for allowing the separator sheet to pass through opposing ends of the box and for allowing adhesive to flow from the first adhesive supply unit. In some such arrangements, the first adhesive supply unit may be a first nozzle. In some such arrangements, the adhesive may flow from a tip of the first nozzle towards the table when the adhesive is applied by the first adhesive supply unit.

In some arrangements, the apparatus for manufacturing an electrode assembly may further include a second adhesive supply unit that may be configured for applying the adhesive. In such arrangements, the first adhesive supply unit and the second adhesive supply unit may be configured for applying the adhesive to either one or both of alternating sections of the separator sheet or alternating ones of the plurality of electrodes supported by the table. In some such arrangements, the first adhesive supply unit and the second adhesive supply unit may be arranged to be on opposite sides of the separator sheet supplied from the separator supply unit. In some arrangements, either one of or both the first adhesive supply unit and the second adhesive supply unit may be upper nozzles in which adhesive applied by such nozzles flows in a downward direction that is in the same direction as the force of gravity from the Earth acting on the adhesive.

In some arrangements, the apparatus for manufacturing an electrode assembly may further include a first lower nozzle configured for applying the adhesive to either one or both of lower portions of each of the first electrodes and lower portions of each of the second electrodes, respectively, in which such adhesive may provide for further adhesion of the separator sheet and the respective electrodes seated on the separator seat. In some such arrangements, the first lower nozzle may be configured for applying the adhesive to the lower portions of each of the first electrodes and the apparatus for manufacturing an electrode assembly may further include a second lower nozzle that may be configured for applying the adhesive to the lower portions of each of the second electrodes.

In some arrangements of the apparatus for manufacturing an electrode assembly, the pair of tensioners may include a first pressure roller and a second pressure roller. In some such arrangements, the first pressure roller may be located within a plane extending between the first adhesive supply unit and the separator guide. In some such arrangements, the second pressure roller may be located within a plane extending between the second adhesive supply unit and the separator guide.

According to another aspect of the present disclosure, an electrode assembly, which for example may be used for a battery cell, may be manufactured by a process. In this process, a separator sheet may be guided along a separator guide. The separator sheet may be supported with a table. The separator sheet guided by the separator guide may be pressed while an adhesive may be applied to a first section of the separator sheet, e.g., to a first region of the separator sheet, supported by the table. The first electrode may be seated on the first adhesive layer applied to the first section of the separator sheet. The second adhesive layer may be applied to an upper portion of an upper portion of the first electrode. The separator sheet may be folded so that a second section of the separator sheet covers the upper portion of the first electrode and the second adhesive layer.

In some arrangements of the process of manufacturing an electrode assembly, a first electrode sheet supplied from a first electrode supply unit may be cut to form a plurality of the first electrodes. In some such arrangements, the first electrode sheet may be unwound from a first electrode reel in being supplied from the first electrode supply unit.

In some arrangements, the separator sheet may be supplied from a separator supply unit. In some such arrangements, the separator supply unit may be a separator reel from which the separator sheet may be unwound when the separator sheet is supplied by the separator supply unit.

In some arrangements of the process of manufacturing an electrode assembly, the pressing of the separator sheet may be performed by a first tensioner, and the first and the second adhesive layers may be applied by a first nozzle. In the process, after covering the upper portion of the first electrode, the separator sheet guided by the separator guide is pressed, e.g., by a second tensioner, in a direction towards the table while a third adhesive layer may be applied, e.g., with a second nozzle, to the second section of the separator sheet supported by the table. A second electrode may be seated on the third adhesive layer applied to the second section of the separator sheet. A fourth adhesive layer may be applied to an upper portion of the second electrode, e.g., from a second nozzle. The separator sheet may be folded, e.g., by a separator guide, so that the third section of the separator sheet covers the second electrode.

In some arrangements of the process of manufacturing an electrode assembly, a second electrode sheet supplied from a second electrode supply unit may be cut to form a plurality of the second electrodes. In some such arrangements, the second electrode sheet may be unwound from the second electrode reel in being supplied from a second electrode supply unit.

In some arrangements of the process of manufacturing an electrode assembly, the table may be translated in a first direction toward a first electrode delivery device or in a second direction toward a second electrode delivery device. In some such arrangements, each of the first electrodes may be transferred from the first electrode delivery device to the table when the table translates in the first direction or each of the second electrodes may be transferred from the second electrode delivery device to the table when the table translates in the second direction.

In some arrangements of the process of manufacturing an electrode assembly, the separator guide, the first nozzle, the second nozzle, the first tensioner, and the second tensioner may be fixed at their respective positions.

In some arrangements of the process of manufacturing an electrode assembly, the separator guide, the first nozzle, the second nozzle, the first tensioner and the second tensioner may simultaneously translate, e.g., linearly, toward the first transfer device or the second transfer device.

In some arrangements of the process of manufacturing an electrode assembly, the table may be fixed at a position.

According to another aspect of the present disclosure, an electrode assembly may be manufacturing by the process of manufacturing an electrode assembly. In arrangements of the electrode assembly, either one of or both the first adhesive layer and the second adhesive layer may have a form of a plurality of dots.

According to another aspect of the present disclosure, an electrode assembly may include a first electrode, a second electrode, and a separator sheet. The separator sheet may have a zigzag shape formed by being folded about the first and the second electrodes such that the first electrode is seated on a first section of the separator sheet, a second section of the separator sheet covers the first electrode the second electrode is seated on the second section, and a third section of the separator sheet covers the second electrode. One or more adhesive layers may be formed between each of the electrodes and the separator sheet. In some arrangements, the separator sheet may be cut to form a separator.

In some arrangements of the electrode assembly, a first adhesive layer may be located between a lower portion of the first electrode and the separator sheet, and a second adhesive layer may be located between the upper portion of the first electrode and the separator sheet. In some such arrangements, the first adhesive layer and the second adhesive layer may be respectively formed by an adhesive applied in the form of a plurality of dots.

According to another aspect of the present disclosure, an electrode assembly for use in a battery cell may include first and second electrodes, a separator sheet from which a separator may be formed, and an adhesive. The first and second electrodes may be alternately stacked and separated from each other by the separator sheet that may be folded between the first and second electrodes in a zigzag shape. The adhesive may be arranged either one of or both between the separator sheet and the first electrode and between the separator sheet and the second electrode. The adhesive may be configured to be dissolved in an electrolytic solution for use in a battery cell only upon application of either one of or both heat and pressure applied to the stacked ones of the first electrode, the second electrode, and the separator sheet.

According to another aspect of the present disclosure, a battery cell may include an electrode assembly according to any of the foregoing electrode assemblies. The battery cell may include a battery case that may house or otherwise enclose the electrode assembly together with an electrolytic solution. The adhesive layer may be dissolved in the electrolytic solution.

According to another aspect of the present disclosure, an electrode assembly, which may be for use in a battery cell, may include first and second electrodes, a separator sheet stacked with the first and the second electrodes in a Z-folding type, and an adhesive. The adhesive may be applied to upper and lower portions of one of or both the first and the second electrodes. In this manner, the one or both of the electrodes to which the adhesive is applied may be prevented or otherwise inhibited, e.g., substantially inhibited, from being displaced from a fixed position in the electrode assembly. According to additional aspects of the present disclosure, an apparatus and a process may be configured for manufacturing the electrode assembly.

The effects of the present disclosure are not limited to the effects mentioned above and additional other effects not described above will be clearly understood from the description of the appended claims by those skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flowchart of a process for manufacturing an electrode assembly according to an example of the present disclosure;

FIG. 2 is a perspective view of a state of process of applying an adhesive from a plurality of nozzles onto a separator sheet being guided by a separator guide and tensioned by a pressure roller according to an example of the present disclosure;

FIG. 3 is a schematic elevation view of an apparatus for manufacturing an electrode assembly according to an example of the present disclosure, which shows a state in which an adhesive is being applied by a first upper nozzle to a first region of a separator sheet while a table moves linearly in a first direction;

FIG. 4 is a schematic elevation view of the apparatus of FIG. 2 , which shows a state in which a first electrode is being seated on the first region of the separator sheet;

FIG. 5 is a schematic elevation view of the apparatus of FIG. 2 , which shows a state in which the adhesive is being applied by the first upper nozzle to an upper portion of the first electrode while the table moves linearly in a second direction;

FIG. 6 is a schematic elevation view of the apparatus of FIG. 2 , which shows a state in which the adhesive is being applied by a second upper nozzle to a second region of the separator sheet while the table moves linearly in the second direction;

FIG. 7 is a schematic elevation view of the apparatus of FIG. 2 , which shows a state in which a second electrode is being seated on the second region of the separator sheet;

FIG. 8 is a schematic elevation view of the apparatus of FIG. 2 , which shows a state in which the adhesive is being applied by the first upper nozzle to the first region of the separator sheet while a first upper nozzle covered by a housing moves linearly in the second direction with the table fixed at a position, according to another example of the present disclosure;

FIG. 9 is a schematic elevation view of the apparatus of FIG. 8 , which shows a state in which the first electrode is being seated on the first region of the separator sheet and the first upper nozzle is moved away from the table;

FIG. 10 is a schematic elevation view of the apparatus of FIG. 8 , which shows a state in which the adhesive is being applied by the first upper nozzle to an upper portion of the first electrode while the first upper nozzle moves linearly in the first direction with the table fixed at a position;

FIG. 11 is a schematic elevation view of the apparatus of FIG. 8 , which shows a state in which the adhesive has been applied by a linear movement of the second upper nozzle in the second direction to the second region of the separator sheet and in which the second electrode is being seated on the second region of the separator sheet;

FIG. 12 is a cross-sectional elevation view of an electrode assembly according to an example of the present disclosure; and

FIG. 13 is an exploded perspective view of a battery cell according to an example of the present disclosure.

DETAILED DESCRIPTION

Hereinafter, various examples of the present disclosure will be described in detail with reference to the accompanying drawings so that those skilled in the art can easily carry them out. The present disclosure may be modified in various ways and is not limited to the examples set forth herein.

Portions that are irrelevant to the description may be omitted to clearly describe the present disclosure.

Further, in the drawings, the size and thickness of each element may be arbitrarily illustrated for convenience of description, and the present disclosure is not necessarily limited to those illustrated in the drawings. In the drawings, the thickness of layers, regions, etc. may be exaggerated for clarity. In the drawings, for convenience of description, the thicknesses of some layers and regions may be exaggerated.

Further, throughout the description, when a portion is referred to as “including” or “comprising” a certain component, it means that the portion can further include other components or elements, without excluding the other components or elements, unless otherwise stated.

Hereinafter, a method of and apparatus for manufacturing an electrode assembly, which may be for use in a battery cell, according to examples of the present disclosure will be described.

Referring to FIGS. 1 and 3 , in a process for manufacturing an electrode assembly, which may be of a Z-folding type, electrode sheets 1111 and 1121 are cut to form an electrode 11 (S101). A separator sheet 122 is seated on a table 16, and an adhesive is applied to the separator sheet (S102). The electrode 11 is seated on the separator sheet 122 (S103). The adhesive is applied to an upper portion (e.g., top surface) of the electrode 11 and the separator sheet 122 (S104). The separator sheet 122 is folded such that the separator sheet covers the electrode 11 (S105). In this manner, the electrode 11 can be prevented from being displaced from a fixed position in the electrode assembly.

Hereinafter, each step shown in the flowchart of FIG. 1 will be specifically described with reference to FIGS. 3 to 7 .

An electrode assembly manufacturing apparatus 1 includes electrode reels 111 and 112 from which electrode sheets 1111, 1112 may be unwound, a separator reel 121 from which separator sheet 122 may be unwound, a table 16, a separator guide 125, a pair of upper nozzles 17, and a pair of pressure rollers 130. A plurality of the electrodes 11 may be formed from the unwound electrode sheets 1111, 1112. The separator sheet 122 is foldable to cover upper and lower surfaces of the electrodes 11 and thereby to be stacked with the electrodes 11. The table 16 supports the electrodes 11 and portions of the separator sheet 122 seated on or over the table. The separator guide 125 guides the separator sheet 122 in a folding direction of the separator sheet 122. The pair of upper nozzles 17 apply an adhesive to at least a part of the separator sheet 122 or the electrode 11 supported by the table 16. The pair of pressure rollers 130 press the separator sheet 122 guided by the separator guide 125.

The electrode reels 111 and 112 are reels on which the electrode sheets 1111 and 1121 are wound and from which the electrode sheets 1111 and 1121 are unwound. When unwound, the electrode sheets 1111 and 1121 are cut to respectively form first electrodes 1112 and second electrodes 1122 or in-process portions of such electrodes. More specifically, according to this example, the first electrode reel 111 is a reel on which the first electrode sheet 1111 is wound, and the first electrode sheet 1111 is unwound from the first electrode reel 111. Further, the second electrode reel 112 is a reel on which the second electrode sheet 1121 is wound, and the second electrode sheet 1121 is unwound from the second electrode reel 112.

Here, the electrode sheets 1111 and 1121 can be manufactured by applying a slurry of an electrode active material, a conductive material, and a binder onto an electrode current collector, and then drying and pressing the slurry. However, manufacturing the electrode sheets 1111 and 1121 is not limited to this process and other processes generally accepted in the art may be utilized for manufacturing the electrode sheets 1111 and 1121 for use in manufacturing the electrode assembly in accordance with the present disclosure.

More specifically, the first electrode sheet 1111 and the second electrode sheet 1121 may include electrode active materials having different polarities from each other. That is, the first electrode 1112 and the second electrode 1122 may be electrodes 11 having different polarities from each other. As an example, if the first electrode 1112 is a cathode, the second electrode 1122 may be an anode. As another example, if the first electrode 1112 is an anode, the second electrode 1122 may be a cathode.

The separator reel 121 is a reel on which the separator sheet 122 is wound, and the separator sheet 122 may be unwound from the separator reel 121. After that, the separator sheet 122 is stacked with the electrodes 11 formed by cutting the electrode sheets 1111 and 1121. Here, the electrodes 11 are alternately stacked onto the separator sheet 122 in a Z-folding type. More specifically, in the present example, when the first electrode 1112 is seated on the separator sheet 122, one side is folded to cover the first electrode 1112, and when the second electrode 1122 is seated, the other side is folded to cover the second electrode 1122 such that the separator sheet 122 has a zigzag form.

The table 16 supports the electrodes 11 and the separator sheet 122 stacked on an upper surface of the table. More preferably, the upper surface of the table 16 is formed substantially flat so that the electrode 11 and the separator sheet 122 can be stably stacked.

As in the example shown, the table 16 may be arranged between first and second electrode supply units configured for conveying the electrodes 11, and in particular between the first electrode reel 111 and the second electrode reel 112. In this manner, the table 16 may linearly reciprocate toward the first electrode reel 111 and the second electrode reel 112.

Thereby, the table 16 may linearly reciprocate between the first electrode reel 111 and the second electrode reel 112 to assist the folding operation of the separator sheet 122 by the separator guide 125 such that a next electrode 11 can be stacked more quickly on the separator sheet 122. In this regard, the process speed and efficiency can be further improved.

The electrode assembly manufacturing apparatus 1 according to the present example may further include a first transfer device 141 that transfers, e.g., by conveying, the first electrode 1112 toward the table 16 and a second transfer device 142 that transfers, e.g, by conveying, the second electrode 1122 towards the table 16. Here, the first transfer device 141 may transfer the first electrode 1112, which is formed by cutting the first electrode sheet 1111 unwound from the first electrode reel 111, toward the table 16. Further, the second transfer device 142 may transfer the second electrode 1122, which is formed by cutting the second electrode sheet 1121 unwound from the second electrode reel 112, toward the table 16.

Thereby, in the present embodiment, the first electrode 1112 and the second electrode 1122 can be respectively transferred to both sides of the table 16 through the first transfer device 141 and the second transfer device 142, to more easily alternately stack the first electrode 1112 and the second electrode 1122 on the separator sheet 122.

Referring to FIGS. 3 and 4 , the electrode assembly manufacturing apparatus 1 may include headers (or heads) 151 and 152 that pick up, e.g., by adsorbing, the electrodes 11 and seat the electrodes on the separator sheet 122. More specifically, the headers 151 and 152 may further include a first header 151 that picks up, e.g., by adsorbing, the first electrode 1112 and seats the first electrode on the separator sheet 122 and a second header 152 that picks up, e.g., by adsorbing, the second electrode 1122 and seats the second electrode on the separator sheet 122. Here, the first header 151 and the second header 152 each can linearly reciprocate toward and away from the table 16.

More specifically, the first header 151 may pick up the first electrode 1112 transferred from the first transfer device 141 toward the table 16, and the second header 152 may pick up the second electrode 1122 transferred from the second transfer device 142 toward the table 16. Further, the first header 151 and the second header 152 may linearly move toward the table 16 and in some arrangements, also in a vertical direction towards and away from the table to allow for clearance due to the increasing height of a stack of the electrodes 11 as the electrodes are stacked.

Thereby, in the present example, the first header 151 and the second header 152 can move the electrode 11 onto and over the table 16 such that each of the headers can stably seat the electrode 11 on incremental respective sections of the separator sheet 122.

Further, the headers 151 and 152 may measure whether or not the first electrode 1112 or the second electrode 1122, respectively, is misaligned for each of the first electrode 1112 or the second electrode 1122 and then correct the position of any misaligned electrode as necessary. In this manner, the headers 151 and 152 are able to precisely seat the electrodes 11 at desired (e.g., target) positions on the separator sheet 122 located on the table 16. Thereby, in the present example, the degree of alignment between each of the electrodes 11 and the separator sheet 122 stacked on the table 16 may be further improved.

A pair of upper nozzles 17 each apply an adhesive to at least a part of the upper portion (e.g., top surface) of the electrode 11, as shown in FIG. 5 . More specifically, the pair of upper nozzles 17 include a first upper nozzle 171 that applies an adhesive to at least a part of the upper portion (e.g., top surface) of the first electrode 1112 and a second upper nozzle 172 that applies an adhesive to at least a part of an upper portion (e.g., top surface) of the second electrode 1122.

The first upper nozzle 171 applies an adhesive to the first region 1221 of the separator sheet 122 seated on the table 16 to form a first adhesive layer 1710 as shown in FIG. 3 , and in greater detail in FIG. 2 . More specifically, as the table 16 moves linearly in a first direction toward the first transfer device 141 as further shown in FIG. 2 , the adhesive applied from the first upper nozzle 171 may form a first adhesive layer 1710 on the first region 1221 of the separator sheet 122. After that, the first electrode 1112 may be seated on the first adhesive layer 1710 and over the first region 1221 of the separator sheet 122 on which the first adhesive layer is formed, as illustrated by the combination of FIGS. 4 and 5 .

Here, the first region 1221 of the separator sheet 122 refers to a region on the separator sheet 122 to which the first electrode 1112 is attached and which is part of a first section of the separator sheet. In some cases in the present disclosure, the first region 1221 refers to a different region, e.g., a third region, in the separator sheet 122 to which a further first electrode 1112 may be attached while the separator sheet is covering the second electrode 1122. Further, the second region 1222 of the separator sheet 122 refers to a region on the separator sheet 122 to which the second electrode 1122 is attached while the separator sheet is covering the first electrode 1112. The second region 1222 is part of a second section of the separator sheet, in which the first and second sections of the separator sheet may refer to flat portions of a separator sheet overlying the table 16 when the separator sheet is folded over the table. In other words, the first electrode 1112 is seated on the first region 1221 of the separator sheet 122, and the second electrode 1122 is seated on the second region 1222 of the separator sheet 122 during manufacturing of the electrode assembly.

Here, it may be preferable that the adhesive is uniformly applied to the first region 1221 of the separator sheet 122. However, when the adhesive is completely applied to the entire surface of the first region 1221 of the separator sheet 122, the amount of the adhesive applied may be excessively large. In such a case, the adhesive may flow to the outside of the separator sheet 122 to contaminate other portions. In this instance, when the secondary battery is manufactured, the power generation function of the battery may not be smooth or may be otherwise degraded.

Therefore, in the present example, the adhesive preferably is applied to a portion or portions of the first region 1221 of the separator sheet 122, e.g., by a spot application method of applying the adhesive in a spot (e.g., as a plurality of spots) or by a line application method of applying the adhesive in a line (e.g., as a plurality of lines). That is, the first adhesive layer 1710 may be preferably formed in a spot pattern or a line pattern or in a combination of these patterns.

In contrast, if the amount of the adhesive applied is too small, the electrode 11 may not be fixed or may not be fixed sufficiently to the separator sheet 122 while the electrode assembly is being moved and thus can be displaced from a fixed position in the electrode assembly. Therefore, it may be preferable that the interval or intervals between each of the regions to which the adhesive is applied are not excessively wide.

The adhesive of the adhesive layer 1710 located between the first region 1221 of the separator sheet 122 and the first electrode 1112 may be dissolved in an electrolytic solution, in preferably the electrolytic solution with which the adhesive layer is contained within a battery cell. More specifically, when the first adhesive layer 1710 is impregnated with an electrolytic solution, the adhesive contained in the first adhesive layer 1710 may be dissolved in the electrolytic solution. Here, the adhesive being dissolved may mean that the adhesive is dissolved into the electrolytic solution. That is, it may mean that the region of the first adhesive layer 1710 is reduced such that only a part of the adhesive is dissolved, or the first adhesive layer is completely eliminated so that the first adhesive layer 1710 does not remain in the first region 1221 of the separator sheet 122.

In one example, the adhesive may be an acrylate-based adhesive. That is, in the present example, when the acrylate-based adhesive is applied as the adhesive to the first region 1221 of the separator sheet 122, the adhesive may be dissolved into the electrolytic solution contained in the final battery cell.

Thereby, in the present example, the first adhesive layer 1710 can fix the first electrode 1112 to the first region 1221 of the separator sheet 122 in the manufacturing process to prevent the displacement of the electrode from a fixed position in the electrode assembly. In addition, the first adhesive layer 1710 may be dissolved in the electrolytic solution contained in the final battery cell, and thus may not hinder the movement of lithium ions between the electrode and the separator, thereby further improving the performance of the battery cell.

Referring to FIGS. 2 to 4 , the electrode assembly manufacturing apparatus 1 according to the present example may include a pair of tensioners, which may be in the form of pressure rollers 130 that press the separator sheet 122, guided from the separator guide 125, against a substrate below the separator sheet 122, whether the table 16 or an electrode 11 (to which an adhesive may be applied). More specifically, the pair of pressure rollers 130, or other tensioners in other arrangements, may be located between the table 16 and the separator guide 125. Here, the pair of pressure rollers 130 may be fixed in position (i.e., not moveable).

In one example, the pair of pressure rollers 130 may have a shape in which a pair of rollers are spaced apart and arranged at a same height relative to a horizontally aligned table, as illustrated, for example, in FIGS. 2 and 3 . Each of the pressure rollers 130 may press one of the opposing surfaces of the separator sheet 122. However, the shape of each of the pressure rollers 130 is not limited to the configuration in this example and can be in different forms as long as the pressure roller has a shape capable of pressing one surface of the separator sheet 122.

Thereby, at least one of the pair of pressure rollers 130 may press one surface of the separator sheet 122, e.g., to constantly control the tension of the separator sheet 122, as shown in FIGS. 2 to 4 , and thereby the position of portions of the separator sheet 122.

In particular, the pair of pressure rollers 130 may be located between the first upper nozzle 171 and the second upper nozzle 172. More specifically, the pair of pressure rollers 130 may include a first pressure roller 1301 and a second pressure roller 1302. Here, the first pressure roller 1301 is located within a plane between the first upper nozzle 171 and the separator guide 125, and the second pressure roller 1302 may be located within another plane between the second upper nozzle 172 and the separator guide 125. That is, the first upper nozzle 171 and the second upper nozzle 172 may apply an adhesive onto the separator sheet 122 while the separator sheet is pressed or otherwise tensioned by at least one of the pair of pressure rollers 130.

In one example, the first pressure roller 1301 can press one surface of the separator sheet 122 in the process of applying the adhesive from the first upper nozzle 171 to the first region 1221 of the separator sheet 122, as shown in FIGS. 2 and 3 . Thereby, the first pressure roller 1301 can keep a constant height difference between the first region 1221 of the separator sheet 122 and the first upper nozzle 171 such that an application amount or an application thickness of the first adhesive layer 1710 may be relatively uniform. Use of the second pressure roller 1302 provides a similar effect.

Further, in a state where the separator sheet 122 is pressed by the first pressure roller 1301, the first upper nozzle 171 can be adjusted to adjust either one of or both the distance and angle between the first region 1221 of the separator sheet 122 and the first upper nozzle 171. In one example, based on the distance between the first region 1221 of the separator sheet 122, the first upper nozzle 171 can be moved so that the distance between the first region 1221 of the separator sheet 122 and the first upper nozzle 171 becomes constant. Alternatively or in conjunction, the first upper nozzle 171 can be rotated so that the angle between the first region 1221 of the separator sheet 122 and the first upper nozzle 171 becomes constant.

Thereby, in a state in which the separator sheet 122 is pressed by the first pressure roller 1301, either one of or both the distance and angle between the first upper nozzle 171 and the first region 1221 of the separator sheet 122 can be kept the same, whereby the application reliability of the adhesive applied from the first upper nozzle 171 to the first region 1221 of the separator sheet 122 can be further improved. Similarly, the second upper nozzle 172 may apply the adhesive to the second region 1222 of the separator sheet 122 in a state in which the separator sheet 122 is pressed by the second pressure roller 1302, as shown in FIGS. 6 and 7 , in order to maintain either one of or both a constant distance and a constant angle between the second upper nozzle and the second region of the separator sheet.

Referring to FIGS. 2 to 7 , the first upper nozzle 171 and the second upper nozzle 172 may be arranged on opposing sides of the separator sheet 122.

That is, the first upper nozzle 171 may apply an adhesive to at least a part of the upper portion of the first electrode 1112 to form the second adhesive layer 1750 before the separator sheet is folded such that the second region 1222 of the separator sheet 122 overlies the upper portion of the first electrode 1112, i.e., such that the second section of the separator sheet covers the upper portion of the first electrode 1112, as in the example shown in FIG. 6 . Further, the second upper nozzle 172 may apply an adhesive to at least a part of the second region 1222 of the separator sheet 122 to form a first adhesive layer 1710 after the separator sheet is folded or while the separator sheet is being folded such that the second region 1222 of the separator sheet 122 overlies, i.e., the second section of the separator sheet covers the upper portion of the first electrode 1112, as in the example shown in FIG. 7 .

Similarly, the second upper nozzle 172 may apply an adhesive to at least a part of the upper portion of the second electrode 1122 to form the second adhesive layer 1750 before the first region 1221, here a third region, of the separator sheet 122 overlies the upper portion of the second electrode 1122, i.e., before a third section of the separator sheet 122 covers the upper portion of the second electrode 1122. Further, the first upper nozzle 171 can apply an adhesive to at least a part of the first region 1221 of the separator sheet 122 to form another first adhesive layer 1710, i.e., a third adhesive layer, after the separator sheet is folded or while the separator sheet is being folded such that the first region 1221 of the separator sheet 122 covers the upper portion of the second electrode 1122.

Here, the table 16 may linearly reciprocate left and right relative to the pair of upper nozzles 17. In this manner, the pair of upper nozzles 17 can apply an adhesive to at least a part of the upper portion of the electrode 11 or the separator sheet 122 while the table 16 is moving linearly in the direction toward the first transfer device 141 or the second transfer device 142 and while respectively passing under the pair of upper nozzles 17.

Additionally, the details of the application of the adhesive by the pair of upper nozzles 17 and the second adhesive layer 1750 may be explained similarly to the first adhesive layer 1710 described above. Here, the first adhesive layer 1710 is formed by applying an adhesive between the lower portion of the electrode 11 and the separator sheet 122, and the second adhesive layer 1750 may be formed by applying an adhesive between the upper portion of the electrode 11 and the separator sheet 122.

Further, as shown in FIGS. 5 and 6 , before the second region 1222 of the separator sheet 122 is placed to overlie the upper portion of the first electrode 1112, the first upper nozzle 171 can apply an adhesive to at least a part of the upper portion of the first electrode 1112 to form a second adhesive layer 1750. At the same time, the second upper nozzle 172 can apply an adhesive to at least a part of the second region 1222 of the separator sheet 122 to form another first adhesive layer 1710, i.e., a third adhesive layer. Moreover, before the first region 1221 of the separator sheet 122 covers the upper portion of the second electrode 1122, the second upper nozzle 172 can apply an adhesive to at least a part of the upper portion of the second electrode 1122 to form another second adhesive layer 1750, i.e., a fourth adhesive layer, while at the same time, the first upper nozzle 171 can apply an adhesive to at least a part of the first region 1221, i.e., third region, of the separator sheet 122 to form another first adhesive layer 1710, i.e., a fifth adhesive layer.

Thereby, as in the present example, the pair of upper nozzles 17 may simultaneously apply an adhesive onto a respective one of the upper portion of the separator sheet 122 and the electrode 11, whereby the process time of the adhesive application process can be reduced, and the process efficiency can be further improved.

Further, as shown in FIG. 5 , each of the pair of pressure rollers 130 may be spaced apart from the second adhesive layer 1750 formed on the upper portion of the first electrode 1112. Thereby, when the table 16 is moved linearly, the adhesive applied on the first electrode 1112 to form the second adhesive layer 1750 may be prevented from directly contacting the pair of pressure rollers 130.

Further, as shown in FIG. 6 , the second pressure roller 1302 can press either one of or both the first adhesive layer 1710 and the second adhesive layer 1750 between the second region 1222 of the separator sheet 122 and the first electrode 1112 in a direction opposite to the moving direction of the table 16, while pressing one surface of the separator sheet 122. Thereby, either one of or both the first adhesive layer 1710 and the second adhesive layer 1750 formed between the first electrode 1112 and the second region 1222 of the separator sheet 122 can be more uniformly applied. A similar result may be obtained when the first pressure roller 1301 presses the first region 1221 of the separator sheet 122 overlying the second electrode 1122 on which the first adhesive layer 1710 is formed.

Referring to FIGS. 6 and 7 , in the present example, a folding direction of the separator sheet 122 can be guided by the separator guide 125. Here, the pair of pressure rollers 130 can assist in guiding the folding direction of the separator sheet 122 in conjunction with the separator guide 125.

In one example, the separator guide 125 may have a form in which a pair of rollers are arranged at a same height above the table 16 when the table is horizontally arranged below the rollers. In a state where the separator sheet 122 is inserted between the pair of rollers, each of the rollers can press and thereby guide the separator sheet 122. However, the shape of the separator guide 125 is not limited to this configuration and can have other forms as long as the separator guide is configured for controlling the folding direction of the separator sheet 122.

Further, the separator guide 125 may include pairs of rollers located above and below the pair of upper nozzles 17 such that a plane extending between the pairs of the rollers passes between the pair of upper nozzles. However, the position and number of the separator guides 125 are not limited to this configuration and other roller positions and quantities may be used so long as the separator guide is configured for controlling the folding direction of the separator sheet 122.

Further, the separator guide 125 can be fixed together with a pair of upper nozzles 17 and a pair of pressure rollers 130 such that the separator guide, the pair of upper nozzles, and the pair of pressure rollers do not move relative to each other. Here, the table 16 linearly reciprocates toward the first transfer device 141 and the second transfer device 142 relative to the separator guide 125, and the separator sheet 122 guided by the separator guide 125 is folded opposite to the moving direction of the table and toward the separator guide 125 so that the separator sheet 122 covers the electrode 11.

In one example, referring to FIGS. 6 and 7 , in a state where the first electrode 1112 is seated on the first region 1221 of the separator sheet 122, the table 16 moves linearly toward the second transfer device 142 so that the second region 1222 of the separator sheet 122 covers the upper portion of the first electrode 1112.

Thereby, as the table 16 linearly reciprocates, the folding process of the separator sheet 122 by the separator guide 125 can be performed simultaneously with the adhesive application process of the pair of upper nozzles 17, so that the process time can be reduced, and the process efficiency can be further improved.

The electrode assembly manufacturing method according to an example of the present disclosure using the electrode assembly manufacturing apparatus 1 can be performed as follows (e.g., for manufacturing a unit cell for an electrode assembly).

First, referring to FIGS. 1 and 3 , when the first electrode sheet 1111 is unwound from the first electrode reel 111, the first cutter 131 cuts the first electrode sheet 1111 to form a plurality of first electrodes 1112 (S101).

Meanwhile, when the separator sheet 122 is unwound from the separator reel 121, the separator sheet 122 is seated on the upper surface of the table 16 in a state of being pressed by the first pressure roller 1301, and the first upper nozzle 171 applies an adhesive to the separator sheet 122 (S102). At this time, the table 16 moves linearly toward the first transfer device 141, and along with the movement of the table 16, the first upper nozzle 171 forms a first adhesive layer 1710 on the first region 1221 of the separator sheet 122.

Further, referring to FIGS. 1 and 4 , the first header 151 may move linearly on the table 16 in a state of picking up, e.g., by adsorbing, the first electrode 1112. When the first header 151 is located above the table 16, as shown in FIG. 4 , the first header 151 seats the first electrode 1112 on the first adhesive layer 1710 over the first region 1221 of the separator sheet 122 on which the first adhesive layer 1710 is formed (S103).

Further, referring to FIGS. 1, 5, and 6 , as the table 16 moves toward the second transfer device 142 after the first electrode 1112 is seated over the first region 1221 of the separator sheet 122, the first upper nozzle 171 applies an adhesive to the upper portion of the first electrode 1112 to form the second adhesive layer 1750. Further, as the table 16 moves towards the second transfer device 142 in a state where one surface of the separator sheet 122 is pressed by the second pressure roller 1302, the second upper nozzle 172 also applies an adhesive to the second region 1222 of the separator sheet 122 to form the additional first adhesive layer 1710, i.e., the third adhesive layer (S104).

Further, referring to FIGS. 1, 6, and 7 , as the table 16 moves toward the second transfer device 142 on the basis of the separator guide 125, one section of the separator sheet 122 is folded so that the second region 1222 of the separator sheet 122 overlies the first electrode 1112 on which the second adhesive layer 1750 is formed (S105).

Meanwhile, as shown in FIG. 3 , when the second electrode sheet 1121 is unwound from the second electrode reel 112, the second cutter 132 cuts the second electrode sheet 1121. In this manner, a plurality of second electrodes 1122 are formed. Subsequently, as shown in FIG. 7 , when the second transfer device 142 transfers the second electrode 1122, the second header 152 picks up, e.g., adsorbs, the second electrode 1122. When the second region 1222 of the separator sheet 122 overlies the first electrode 1112, the second header 152 carrying, e.g., adsorbing, the second electrode 1122 moves toward a position overlying the second region 1222 at the second section of the separator sheet to seat the second electrode 1122 over the second region 1222 and on the additional first adhesive layer 1710, i.e., third adhesive layer, formed on the second region 1222.

Similarly to the use of the first upper nozzle 171 shown in FIG. 5 , the second upper nozzle 172 applies an adhesive onto the second electrode 1122. Here, as the table 16 moves towards the first transfer device 141, the second upper nozzle 172 may form a second adhesive layer 1750 on the second electrode 1122.

Then, as the table 16 moves toward the first transfer device 141 due to the separator guide 125, the other side of the separator sheet 122 is folded, so that the additional first region 1221 at a third section of the separator sheet 122 covers the second electrode 1122 on which the additional second adhesive layer 1750, i.e., fourth adhesive layer, is formed.

That is, by repeating the above processes, the electrode assembly manufacturing process according to an example of the present disclosure can be performed, e.g., to sequentially form a plurality of unit cells of the electrode assembly.

When such electrode assembly manufacturing process according to the examples of the present disclosure is performed, the adhesives are respectively applied to the upper and lower portions of the electrodes 11 at the time of stacking the electrodes 11 and the separator sheet 122 in a Z-folding type, thereby preventing or at least inhibiting the electrodes 11 from being displaced from a fixed position in the electrode assembly.

In another example, an electrode assembly manufacturing apparatus 1 a is substantially the same as the electrode assembly manufacturing apparatus 1 described above with reference to FIGS. 2 to 7 , and only the parts that differ from the electrode assembly manufacturing apparatus 1 will be described below.

The apparatus 1 a may also be used for a process of manufacturing an electrode assembly according to the present disclosure, such as for example the process shown in FIG. 1 .

Referring to FIG. 8 , in the electrode assembly manufacturing apparatus 1 a of the present example, the table 16 a may be fixed such that the table is not moveable. Thereby, the electrode 11 and the separator sheet 122 can be stacked on the table 16 in a fixed state such that a degree of alignment of the electrode 11 and the separator sheet 122 can be further improved.

Further, each of the separator guide 125, the first upper nozzle 171 a, and the second upper nozzle 172 a may be moveable, e.g., may linearly reciprocate left and right, relative to the table 16 a. In one example, as shown in FIG. 8 , as the first upper nozzle 171 a moves linearly in a second direction toward the second transfer device 142 relative to the table 16 a, the first adhesive layer 1710 may be formed by applying an adhesive to the first region 1221 of the separator sheet 122.

Further, the pair of pressure rollers 130 may move together with the separator guide 125, the first upper nozzle 171 a, and the second upper nozzle 172 a in the state of pressing one surface of the separator sheet 122. In one example, the first pressure roller 1301 moves together with the second pressure roller 1302, the first upper nozzle 171 a and the second upper nozzle 172 a in the state of pressing one surface of the separator sheet 122. Thereby, the pair of pressure rollers 130 can maintain the tension of the separator sheet 122. In addition, the distance between the first upper nozzle 171 a and the second upper nozzle 172 a and the separator sheet 122 may be maintained.

As an example, the electrode assembly manufacturing apparatus 1 a according to the present example may further include a carriage such as a frame, which may be a moving box 18, that houses the separator guide 125, the first upper nozzle 171 a, and the second upper nozzle 172 a. That is, in the electrode manufacturing apparatus 1 a of the present example, as the moving box 18 moves reciprocally in the first and the second directions, the separator guide 125, the first upper nozzle 171 a, and the second upper nozzle 172 a can move reciprocally with the moving box at the same time.

Thereby, the distance between the first upper nozzle 171 a and the separator guide 125 and the distance between the second upper nozzle 172 a and the separator guide 125 can be kept constant, and the application reliability of the adhesive applied from the first upper nozzle 171 a and the second upper nozzle 172 a can be improved.

Further, either one or both the orientation and position of the first upper nozzle 171 a and/or the second upper nozzle 172 a in the moving box 18 may be adjusted so that the distance or angle between one of or both the first upper nozzle 171 a and the second upper nozzle 172 a and the separator 122 can be adjusted or maintained due to the change in orientation of the moving box. However, even in this case, the interval between the first upper nozzle 171 a and the separator guide 125 in the moving box 18 and the interval between the second upper nozzle 172 a and the separator guide 125 in the moving box 18 may be kept the same so that the application reliability of the adhesive applied from the first upper nozzle 171 a and the second upper nozzle 172 a can be further improved.

The electrode assembly manufacturing process according to another example of the present disclosure using such an electrode assembly manufacturing apparatus is performed as follows.

First, referring to FIGS. 1 and 8 , when the first electrode sheet 1111 is unwound from the first electrode reel 111, the first cutter 131 cuts the first electrode sheet 1111 to form a plurality of first electrodes 1112 (S101).

Meanwhile, when the separator sheet 122 is unwound from the separator reel 121, the separator sheet 122 is seated on the upper surface of the table 16 a in the state of being pressed by the first pressure roller 1301, and the first upper nozzle 171 a applies an adhesive to the separator sheet 122 (S102). At this time, the first upper nozzle 171 a forms a first adhesive layer 1710 on the first region 1221 of the separator sheet 122 while linearly moving toward the second transfer device 142.

Further, referring to FIGS. 1 and 9 , the first header 151 can move linearly on the table 16 in a state of picking up, e.g., adsorbing, the first electrode 1112. When the first header 151 is located above the table 16 a, as shown in FIG. 9 , the first header 151 allows the first electrode 1112 to be seated on the first region 1221 of the separator sheet 122 on which the first adhesive layer 1710 is formed (S103).

Further, referring to FIGS. 1, 10, and 11 , as the first upper nozzle 171 a moves toward the first transfer device 141 after the first electrode 1112 is seated on the first region 1221 of the separator sheet 122, the first upper nozzle 171 a applies an adhesive to the upper portion of the first electrode 1112 to form a second adhesive layer 1750. Further, as the second upper nozzle 172 a also moves toward the first transfer device 141 in a state where one surface of the separator sheet 122 is pressed by the second pressure roller 1302, an adhesive is applied to the second region 1222 of the separator sheet 122 to form an additional first adhesive layer 1710 (S104).

Further, referring to FIGS. 1, 10, and 11 , as the separator guide 125 and the pair of pressure rollers 130 move toward the first transfer device 141 relative to the table 16 a, one side of the separator sheet 122 is folded so that the second region 1222 of the separator sheet 122 overlies the first electrode 1112 on which the second adhesive layer 1750 is formed (S105).

Meanwhile, as shown in FIG. 8 , when the second electrode sheet 1121 is unwound from the second electrode reel 112, the second cutter 132 cuts the second electrode sheet 1121. In this manner, a plurality of second electrodes 1122 are formed. Subsequently, as shown in FIG. 11, when the second transfer device 142 transfers, e.g., by conveying, the second electrode 1122, the second header 152 picks up, e.g., adsorbs, the second electrode 1122. When the second region 1222 of the separator sheet 122 overlies the first electrode 1112, the second header 152 carrying, e.g., adsorbing, the second electrode 1122 moves toward a position overlying the second region 1222 to seat the second electrode 1122 over the second region 1222 and on the first adhesive layer 1710 formed on the second region 1222.

Then, similar to the step shown in FIG. 10 , the second upper nozzle 172 a applies an adhesive to the upper portion of the second electrode 1122. Here, as the second upper nozzle 172 a moves toward the second transfer device 142, the second upper nozzle 172 a may form an additional second adhesive layer 1750 on the second electrode 1122.

After that, as the separator guide 125 and a pair of pressure rollers 130 move toward the second transfer device 142 relative to the table 16 a, the other side of the separator sheet 122 is folded so that the additional first region 1221 of the separator sheet 122, i.e., third region, overlies the second electrode 1122 on which the additional second adhesive layer 1750 is formed.

That is, by repeating the above processes, the electrode assembly manufacturing method according to an example of the present disclosure can be performed, e.g., to sequentially form a plurality of unit cells of the electrode assembly.

When such electrode assembly manufacturing process according to the examples of the present disclosure is performed, the adhesives are respectively applied to the upper and lower portions of the electrodes 11 at the time of stacking the electrodes 11 and the separator sheet 122 in a Z-folding type, thereby preventing or at least inhibiting the electrodes 11 from separating from a fixed position in the electrode assembly.

Referring to FIGS. 7, 11, and 12 , in the electrode assembly 10 in which electrodes and a separator sheet are alternately stacked according to another example of the present disclosure, the separator sheet 122 has a zigzag shape formed by being folded about at least a first electrode 1112 and a second electrode 1122.

Here, the separator sheet 122 is folded in a state where the first electrode 1112 is seated on the first region 1221 of the separator sheet so that the second region 1222 of the separator covers the first electrode. Further, the separator sheet 122 is folded in a state where the second electrode 1122 is seated on the second region 1222 of the separator so that the additional first region 1221 of the separator sheet covers the second electrode.

In particular, the electrode assembly 10 according to the present example may be configured such that the electrodes 11 can be stacked one by one on the first region 1221 or the second region 1222 of the separator sheet 122. At this time, after measuring the presence or absence of misalignment, the electrode 11 can be stacked at an accurate position on the separator sheet 122 in a state where the position is corrected if necessary. Thereby, the electrode assembly 10 according to the present embodiment can be further improved in the degree of alignment between each of the electrodes 11 and the separator sheet 122.

Here, an adhesive layer 1700 is formed between each of the electrodes 11 and the separator sheet 122. More specifically, the adhesive layer 1700 includes a first adhesive layer 1710 and a second adhesive layer 1750. The first adhesive layer 1710 may be located between the lower portions of each of the electrodes 11 and the separator sheet 122, and the second adhesive layer 1750 may be located between the upper portions of each of the electrodes 11 and the separator sheet 122.

In one example, the first adhesive layer 1710 and the second adhesive layer 1750 may be formed by applying an adhesive in the form of a plurality of dots, respectively, as disclosed, for example, in U.S. Patent Application Publication No. 2022/0158304 A1, the disclosure of which is hereby incorporated by reference herein in its entirety. However, as described above in the battery cell manufacturing apparatus 1, the shapes of the first adhesive layer 1710 and the second adhesive layer 1750 are not limited to this configuration, and may be formed in various shapes. For example, either one of or both the first adhesive layer 1710 and the second adhesive layer 1750 may be formed by applying an adhesive in the form of a plurality of lines, e.g., parallel lines, cross-hatch, or other configurations. In some arrangements, an adhesive layer or adhesive layers having dots and lines may be utilized.

Thereby, the electrode assembly 10 according to the present example forms an adhesive layer 1700 between the electrodes 11 and the separator sheet 122, and thus even in the case of a low-cost separator whose adhesive strength is relatively low, the electrodes 11 and the separator can be stably fixed to each other, and thereby prevent or at least inhibit the electrodes 11 from being displaced from their fixed positions in the electrode assembly. In addition, the electrode assembly 10 of the present example covers the upper and lower portions of each of the electrodes 11 in a shape in which a separator sheet 122 is folded so that the degree of alignment of the electrodes 11 and the efficiency of the process can be further improved.

Further, since there is no need to perform a laminating process as in the conventional case, it is possible to reduce the defective rate in the process caused by high heat and pressure. Moreover, since the laminator can be removed, the volume of the manufacturing apparatus can be reduced and the manufacturing process can be simplified.

The separator sheet 122 may, for example, comprises or consist of a flexible and electrically insulating material, in particular a porous, flexible and electrically insulating material, e.g., a resin film such as a polyolefin-based resin film.

The separator according to the example described herein may be a CCS (Ceramic Coated Separator. Generally, the separator may have a raw film and a coating layer formed on at least one surface of the raw film, in which the coating layer may include alumina powder and a binder for aggregating them. Safety Reinforced Separator (SRS) has a large amount of binder coated on the surface of the coating layer, but CCS may not have the binder coated on the surface of the coating layer or may have a much lower surface binder content as compared with SRS. For example, in the case of the CCS separator according to the present example, the content of the binder coated on the surface of the coating layer of the separator may be about 3 wt % or less, and in some other examples about 2 wt % or less, and in still other examples about 1 wt % or less.

When the separator is CCS, the internal electrode contained in the electrode assembly may be transferred in an unfixed state, and thus alignment may be disturbed during transfer. Of course, when the separator is CCS, it can be fixed with heat and pressure, but the alignment of the internal electrodes may be disturbed even in the process of transferring to the fixing device for heat and pressure after forming the stacked body of the electrode and the separator. Further, there is a disadvantage in that an expensive separator having a high binder content must be used in order to attach the electrode and the separator by heat and pressure. On the contrary, according to the present example, it is possible to increase the fixing force between the separator and the electrodes while preventing the alignment of the internal electrodes from being disturbed during transfer.

Referring to FIGS. 7 and 11 to 13 , a battery cell according to an example of the present disclosure is a battery cell including the electrode assembly 10 described above, in which the battery cell includes a battery case 50 for housing the electrode assembly 10 together with an electrolytic solution. The adhesive layer 1700 may be dissolved (e.g., partially or entirely) in the electrolytic solution, e.g., by application of either one of or both heat and pressure.

Here, a fixing member such as a fixing tape 30 may be attached to the outside of the electrode assembly 10. Thereby, the stacked alignment state of the electrode 11 and the separator sheet 122 can be maintained. The electrode assembly 10 to which the fixing tape 30 is attached may be referred to as a final electrode assembly 20.

The battery case 50 includes an electrode assembly 10, a receiving part 60 to which the final electrode assembly 20 is mounted, and a sealing part 70 for sealing the outer periphery of the receiving part 60. In one example, the battery case 50 may be a laminated sheet including a resin layer and a metal layer. More specifically, the battery case 50 may be made of a laminated sheet and may include an outer resin layer for forming the outermost shell, a blocking metal layer for preventing the penetration of a material, and an inner resin layer for sealing.

Further, the receiving part 60 of the battery case 50 may be configured to house an electrolytic solution together with the electrode assembly 10. Here, the adhesive layer 1700 contained in the electrode assembly 10 may be dissolved into the electrolytic solution. In particular, in the battery cell according to the present example, in an activation step such as a formation step, the adhesive layer 1700 contained in the electrode assembly 10 may be dissolved into an electrolytic solution under either one of or both high temperature and pressure conditions.

More specifically, in the battery cell according to the present example, when the adhesive layer 1700 formed between the electrodes 11 of the electrode assembly 10 and the separator sheet 122 is dissolved into the electrolytic solution, the adhesive may hardly remain on the surface of the electrodes 11 (e.g., may be dissolved entirely or almost entirely) or may not be completely eliminated (e.g., may only be dissolved partially).

The separator sheet 122 may generally be a porous sheet. In this regard, a part of the adhesive may permeate into the separator sheet 122. However, even in the case of the adhesive layer 1700 penetrated into the separator sheet 122, the adhesive may be mostly dissolved in the electrolytic solution or may be completely dissolved. In this process, traces of adhesive from the application of the adhesive layer 1700 may remain on the separator sheet 122.

Here, the application trace of the adhesive layer 1700 means that the adhesive component contained in the adhesive layer 1700 does not remain, but a part of the outer surface of the separator sheet 122 is deformed or otherwise modified by the adhesive layer 1700. However, the present disclosure is not limited thereto, and the application trace of the adhesive layer 1700 may mean traces that can confirm the prior application of the adhesive in various ways, like traces that can confirm with the naked eye the application of the adhesive. Thereby, the application trace of the adhesive layer 1700 formed on the separator sheet 122 may be formed at the same position as the position where the adhesive is applied.

Therefore, the battery cell according to the present example can prevent the performance degradation and realize excellent battery performance because the adhesive layer 1700 is completely or at least sufficiently dissolved on the surfaces of the electrodes 11 or the separator 122, and the unreacted region due to the adhesive layer 1700 has completely or at least sufficiently disappeared.

Although preferred embodiments of the present disclosure have been described in detail above, the scope of the present disclosure is not limited thereto, and various modifications and improvements made by those skilled in the art using the basic concepts of the present disclosure, which are defined in the appended claims, also falls within the scope of the present disclosure.

DESCRIPTION OF REFERENCE NUMERALS

-   -   1, 1 a: cell manufacturing apparatus     -   11: electrode     -   16, 16 a: table     -   17: nozzle     -   111: first electrode reel     -   112: second electrode reel     -   121: separator reel     -   122: separator sheet     -   125: separator guide     -   130: pressure roller     -   131: first cutter     -   132: second cutter     -   141: first transfer device     -   142: second transfer device     -   151: first header     -   152: second header     -   171, 171 a: first upper nozzle     -   172, 172 a: second upper nozzle     -   1111: first electrode sheet     -   1112: first electrode     -   1121: second electrode sheet     -   1122: second electrode     -   1221: first region     -   1222: second region     -   1301: first pressure roller     -   1302: second pressure roller     -   1710: first adhesive layer     -   1750: second adhesive layer 

1. An apparatus for manufacturing an electrode assembly, the electrode assembly comprising a plurality of electrodes and a separator folded in a zigzag manner around alternating side portions of each of the electrodes and covering upper and lower surfaces of each of the electrodes, the apparatus comprising: a separator supply unit configured for supplying a separator sheet from which the separator is formed; a table configured for supporting the plurality of electrodes and sections of the separator sheet; a separator guide configured for guiding the separator sheet to fold in a particular folding direction; a first adhesive supply unit configured for applying an adhesive to either one or both of at least some of the sections of the separator sheet and at least one of the plurality of electrodes supported by the table; and a pair of tensioners each configured for pressing an uppermost section of the separator sheet guided by the separator guide.
 2. The apparatus for manufacturing an electrode assembly according to claim 1, wherein the pair of tensioners are located between the table and the separator guide when the pair of tensioners, the table, and the separator guide are aligned along an axis.
 3. The apparatus for manufacturing an electrode assembly according to claim 1, further comprising: a first transfer device configured for conveying a first electrode of the plurality of electrodes toward the table; and a second transfer device configured for conveying a second electrode of the plurality of electrodes toward the table, wherein the first transfer device and the second transfer device are arranged to be on opposite sides of the separator sheet unwound from the separator reel.
 4. The apparatus for manufacturing an electrode assembly according to claim 3, further comprising: a first header configured for adsorbing and then seating the first electrode on a first section of the separator sheet; and a second header configured for adsorbing and then seating the second electrode on a second section of the separator sheet, wherein the first header and the second header are arranged to be on opposite sides of the separator sheet supplied from the separator supply unit.
 5. The apparatus for manufacturing an electrode assembly according to claim 3, wherein the separator guide, the first adhesive supply unit, and the pair of tensioners are fixed at their respective positions, and wherein the table is configured for translation in a first direction toward the first transfer device and in a second direction toward the second transfer device.
 6. The apparatus for manufacturing an electrode assembly according to claim 3, wherein the table is fixed at a position, and wherein each of the separator guide, the first adhesive supply unit, and the pair of tensioners may be configured for translation in a first direction toward the first transfer device and in a second direction toward the second transfer device.
 7. The apparatus for manufacturing an electrode assembly according to claim 6, further comprising a moveable frame configured for carrying the separator guide and the first adhesive supply unit.
 8. The apparatus for manufacturing an electrode assembly according to claim 1, further comprising a second adhesive supply unit configured for applying the adhesive, wherein the first adhesive supply unit and the second adhesive supply unit are configured for applying the adhesive to either one or both of alternating sections of the separator sheet or alternating ones of the plurality of electrodes supported by the table, and wherein the first adhesive supply unit and the second adhesive supply unit are arranged to be on opposite sides of the separator sheet supplied from the separator supply unit.
 9. The apparatus for manufacturing an electrode assembly according to claim 1, wherein the pair of tensioners comprise a first pressure roller and a second pressure roller, wherein the first pressure roller is located within a plane extending between the first adhesive supply unit and the separator guide, and wherein the second pressure roller is located within a plane extending between the second adhesive supply unit and the separator guide.
 10. A method for manufacturing an electrode assembly, the method comprising the steps of: guiding a separator sheet along a separator guide; supporting the separator sheet with a table; pressing the separator sheet guided while applying a first adhesive layer to a first section of the separator sheet supported by the table; seating a first electrode on the first adhesive layer applied to the first section of the separator sheet; applying a second adhesive layer to an upper portion of the first electrode; and folding the separator sheet so that a second section of the separator sheet covers an upper portion of the first electrode and the second adhesive layer.
 11. The method for manufacturing an electrode assembly according to claim 10, wherein the pressing step is performed by a first tensioner, the first adhesive layer applying step and the second adhesive layer applying step are performed by a first nozzle, and after the step of covering the upper portion of the first electrode, the method further comprises: pressing, with a second tensioner, the separator sheet guided by the separator guide in a direction towards the table while applying, with a second nozzle, a third adhesive layer to the second section of the separator sheet supported by the table; seating a second electrode on the third adhesive layer applied to the second section of the separator sheet; applying a fourth adhesive layer to an upper portion of the second electrode from the second nozzle; and folding the separator sheet so that the third section of the separator sheet covers the second electrode.
 12. The method for manufacturing an electrode assembly according to claim 11, the method further comprising: translating the table in a first direction toward a first electrode delivery device or in a second direction toward a second electrode delivery device; and transferring the first electrode from the first electrode delivery device to the table when the table translates in the first direction or transferring the second electrode from the second electrode delivery device to the table when the table translates in the second direction.
 13. The method for manufacturing an electrode assembly according to claim 11, wherein the separator guide, the first nozzle, the second nozzle, the first tensioner, and the second tensioner are fixed at their respective positions.
 14. The method for manufacturing an electrode assembly according to claim 11, the method further comprising: translating the separator guide, the first nozzle, the second nozzle, the first tensioner and the second tensioner simultaneously toward the first transfer device or the second transfer device.
 15. The method for manufacturing an electrode assembly according to claim 14, wherein the table is fixed at a position.
 16. An electrode assembly manufactured by the method of claim
 10. 17. The electrode assembly according to claim 16, wherein either one of or both the first adhesive layer and the second adhesive layer have a form of a plurality of dots.
 18. A battery cell comprising the electrode assembly of claim 16, wherein the battery cell comprises a battery case that houses the electrode assembly together with an electrolytic solution, and wherein the adhesive layer is dissolved in the electrolytic solution.
 19. An electrode assembly for use in a battery, the electrode assembly comprising: a separator sheet, first and second electrodes alternately stacked and separated from each other by the separator sheet that is folded between the first and second electrodes in a zigzag shape; and an adhesive arranged either one of or both between the separator sheet and the first electrode and between the separator sheet and the second electrode, wherein the adhesive is configured to be dissolved in an electrolytic solution for use in a battery cell only upon application of either one of or both heat and pressure applied to the stacked ones of the first electrode, the second electrode, and the separator sheet.
 20. A battery comprising the electrode assembly of claim 19, wherein the battery cell comprises a battery case that houses the electrode assembly together with an electrolytic solution, and wherein the adhesive layer is dissolved in the electrolytic solution. 